When it comes to screen making for screen printing, image quality is one of the most critical factors that determine the final print’s sharpness, detail, and consistency. Over the years, advancements in computer-to-screen (CTS) technology have transformed how screens are created, offering improvements in efficiency and precision over traditional film positives.

But how do these different technologies compare? And which solution is best for your shop? In this blog post, we’ll compare the image quality of film positives, inkjet CTS, wax CTS, and laser-to-screen (LTS) systems, focusing specifically on three key factors: resolution, cost of operation, and maintenance.

Understanding Screen Making Technologies

1. Film Positives (Traditional Method)

For decades, screen printers have used film positives to expose screens. The process involves printing a design onto a transparent film using an inkjet or laser printer, which is then used in conjunction with a light source to harden the emulsion on the screen.

Pros:

• Well-established and widely understood process
• Can produce high-quality results with proper film and printer settings
• No direct screen contact, reducing the chance of damage

Cons:

• Requires a vacuum exposure unit for best results
• Need film storage and organization space
• Film can degrade, tear, or become scratched over time
• Ink density and dot quality depend on the printer and RIP software used
• Additional consumables (films, ink, and chemicals) increase operational costs

2. Inkjet Computer-To-Screen CTS

Inkjet-based computer-to-screen (CTS) technology eliminates the need for film by directly jetting UV-blocking ink onto a coated screen. The exposed screen is then cured and developed.

Resolution:

• Inkjet CTS offers relatively high resolution, but the smallest dot size is dependent on the nozzle precision of the inkjet printheads.
• Fine detail and halftones can be reproduced effectively, but dot gain can occur, impacting image sharpness.

Cost of Operation:

• Requires specialized ink that can add to operating expenses.
• Ink consumption varies depending on image density, leading to inconsistent costs.
• Higher upfront investment compared to film positives.

Maintenance:

• Inkjet heads can clog if not maintained properly, requiring regular purges.
• Routine cleaning and calibration needed to ensure optimal performance.
• Humidity control may be necessary to prevent ink drying in the heads.

3. Wax Computer-To-Screen CTS

Wax CTS technology utilizes hot wax to create an opaque stencil image directly on a coated screen. This method enhances dot control and prevents ink bleed commonly associated with inkjet systems.

Resolution:

• Produces very sharp halftones and crisp details.
• More consistent dot shape than inkjet due to wax’s ability to solidify quickly.
• Less dot gain compared to inkjet CTS.

Cost of Operation:

• Uses wax instead of ink, reducing potential clogging issues.
• Wax ribbons can be costly but are predictable in terms of usage.
• Initial investment is high but can reduce long-term consumable expenses.

Maintenance:

• Less maintenance required compared to inkjet CTS.
• Printheads last longer due to reduced risk of clogging.
• Requires periodic head cleaning but is less frequent than inkjet systems.

4. Laser-to-Screen LTS - Subset of Computer-To-Screen CTS

The LTS 8012 from Chromaline is a cutting-edge laser-to-screen (LTS) system that directly images screens using laser exposure technology. Instead of applying ink or wax, the laser selectively hardens the emulsion on the screen without requiring a separate exposure step.

Resolution:

• Highest resolution among all CTS methods.
• Lasers produce sharp, well-defined edges with minimal dot gain.
• Perfect for fine details, halftones, and high line-count images.

Cost of Operation:

• Eliminates consumables such as ink, wax, or film.
• Lower long-term operational costs compared to inkjet or wax CTS.
• Energy-efficient and reduces waste.

Maintenance:

• Minimal maintenance required.
• No printheads to clog, purge, or replace.
• Requires periodic laser alignment and minor cleaning of optics.

Which Technology is Right for You?

Ready to Upgrade Your Screen Making?

Choosing the right computer-to-screen (CTS) technology depends on your shop’s priorities. If you prioritize cost efficiency and minimal maintenance, Laser-to-Screen (LTS 8012) is the superior choice. If you’re looking for a lower initial investment and can manage maintenance, wax or inkjet CTS might be a suitable alternative. Traditional film positives still work well but come with higher consumable costs and process variability.

With Chromaline’s LTS 8012, you get unmatched resolution, cost savings, and ease of maintenance, making it the best long-term investment for screen printing professionals. Learn more about Chromaline's LTS 8012 and how it can transform your shop. Contact Chromaline today for a free consultation.